IPLOG

Heating System Controlled by PLC

Increasing energy prices pressure on replacing of old gas boilers with new
condensing boilers with higher efficiency. However, for a truly efficient
operation it is necessary to guarantee the individual heating of rooms to
the optimum temperature depending on the type of workplace and its
actual use. Therefore, in these applications we recommend using the PLC
together with temperature measurement in all rooms with radiators and
controlling radiators with thermoelectric heads. Convenient management
of the entire system ensures visualization software.

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 Heating System Controlled by PLC
IPLOG
Description of a Typical Application 2G/3G/4G MODBUS IEC 61131-3

We have used our own production facility to verify that the system is working properly and to
derail it. Two obsolete gas boilers and radiators fitted with thermal actuators with manual
control ceased to reliable function in 2017. As a replacement, we chose the Vaillant VU INT II
356 / 5-5 condensing boiler. Once the boiler has been put into operation, we have prepared the
hardware needed for its management:
v The PLC IPLOG-G2-05 and three I/O modules RE8.1-05 were installed in the central cabinet
v The radiators were fitted with 24 VAC controlled thermal heads.
v Temperatures in all rooms have started to measure IPSEN-T2 thermometers.

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Ethernet PWR |ST

R E SE T
1| 2
3| 4
Modbus USB

Relay Output HOST

P1

GSM

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PLC IO Modules
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°C °C
°C

Laboratory 23°C Stock 22°C Corridor 20°C

Another challenge was control program. The METEL IDE programming software with hundreds of
available functions defined in IEC61131-3 simplifies this task, because also allows you to prepare
customized blocks. To create a customized block, simply enter the keyword FUNCTION_BLOCK at
the beginning of the ST program with the desired name, define constants, variables, inputs,
outputs and end the program with keyword END FUNCTION_BLOCK. Clicking
Klíčové slovo Build all then generates a
FUNCTION_BLOCK thermostat
VAR CONSTANT a název bloku function block that can be
LEVEL_NUM : INT := 5; Definice used in the FB language. In our
LEVEL_TEMP_STEP : INT := 10; konstant
END_VAR project, for example we used this
VAR procedure to create a function
(* local vars *)
LEVEL_SIZE : INT; Definice block thermostat with inputs
LEVEL_CURR : INT := 5; proměnných temp (the current temperature),
devi : INT;
END_VAR temp_required ( required temp.)
VAR_INPUT and hyst (hysteresis). Depending
temp : INT := 210;
(* temp_is_connected : BOOL Definice on the current input values, the
:= TRUE; *) vstupů percentage output (how much it
temp_required : INT := 210 ;
hyst : INT := 10; needs to heat) is calculated.
END_VAR
VAR_OUTPUT Definice
burn_perc : INT; výstupů
END_VAR
Program Program
END_FUNCTION_BLOCK

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 Heating System Controlled by PLC

IPLOG
Description of a Typical Application 2G/3G/4G MODBUS IEC 61131-3

The output from the generic thermostat block is recalculated by the burn_reduce block. If the
expected room temperature increase does not happen, the burn_reduce block will correct the
calculation. The result is the additional switching on of one or more radiators. The percentage
calculated by the burn_reduce block converts the burn2bool block to the number of radiators
to heat.

Graph with Progressive Switching ON and OFF of Radiators

In the event there is no demand for heating with at least one radiator, the PLC boiler will
automatically switch off. An outdoor equithermal sensor is also connected to the system to help
control the boiler's output power depending on the outside temperature.
Other Useful Features
LOGGER - in each such system, it is advisable
to know in addition to the current data its
history. Therefore, all measured data are
stored in a local MySQL database in the PLC
and in the visualization software database.
WATCHDOG – block wdg.fbd periodically
writes value 1 into file. This writing is
periodically controlled by a Linux system and
in the case of deadlock the program restarts
it and informs the relevant person by SMS
message.
HARMONOGRAMS AND VISUALIZATION - the
IFTER-EQU visualization software is used to
visualize the whole system and to set
schedules to determine when it is warming to
daytime temperature and when it is not used
at night.

The heating-controlled PLC system has helped greatly reduce the cost of
heating. Each room is only heated to the optimum temperature. When not in
use, the temperature is automatically reduced, which further increases cost
savings. The built-in GSM router provides remote online surveillance and alerts
about emergency situations via SMS.

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 Heating System Controlled by PLC
IPLOG
Ordering Information 2G/3G/4G MODBUS IEC 61131-3

METEL DEVICE NAME AND CODE NOTE

(1)
Industrial PLC with 2G/3G IPLOG-G2-05 PLC unit with 2G / 3G modem, RS485 Modbus RTU bus for
Modem 5607-0000 connection of external IO modules and sensors, 2x alarm /
digital 5 V inputs.
(1)
You can configure the PLC with other inputs, outputs,
and serial interfaces in the online configurator at http://
www.metel.eu/en/iplog-configurator.

Bus IO Module RE8.1-05-BOX Bus IO module with: 8x NO 230V relay outputs, 3x

5000-0507 optically isolated 230V inputs, 2x NOC 230V relay
outputs, 1x RS485 Modbus port, 2x alarm / digital 5V
inputs, operating temperature -40°C to +70°C, 600W
integrated overvoltage protections

Bus T/RH Sensor IPSEN-TH2-MOD RS485 Modbus-RTU bus temperature / humidity sensor,
5-202-283 temperature: -40°C to +80°C, relative humidity: 0-100%
RH, accuracy: ± 0.4°C / 3% RH (25°C) , 12VDC

3RD PARTY DEVICES

24V Thermoelectric Heads The IFTER-EQU Visualization Software

For more information about the applications, visit: http://www.metel.eu/en/products/succes-stories

METEL s. r.o., Žižkův kopec 617

55203 Česká Skalice, CZECH REPUBLIC
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Technical info: info@metel.eu
Business info: metel@metel.eu

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